Manufacturing Commons^™

Improving Manufacturing Processes Through Energy Monitoring, Andrew Grzelak

Purdue Polytechnic Masters Theses

Energy efficiency and sustainability are very popular topics in the current field of manufacturing. With the increase in use of automation technology as well as the recent growth in the area of energy management, there is much focus on the overall improvement of manufacturing processes. For this research a project was completed to create a system that could improve both process efficiency as well as decrease energy consumption. By taking a look at the machine level energy consumption of an automated piece of manufacturing equipment, by eliminating waste in process, both energy efficiency and operational efficiency can be improved.

Using …

Acoustic Emission Detection Of Metals And Alloys During Machining Operations, Jameson K. Nelson

Purdue Polytechnic Masters Theses

Nelson, Jameson K. M.S., Purdue University, May 2012. Acoustic Emission Detection of Metals and Alloys During Machining Operations. Major Professor: Rodney G. Handy.

Practical correlation between material deformation attributes and theoretical concepts of machining has proven difficult to attain. The purpose of this study was to further explore trends and relationships using acoustic emission detection of materials undergoing single-point lathe turning machine processes. The majority of machining experiments that incorporate acoustic emissions focuses on tool degradation for the purposes of optimizing consumables required to manufacture mechanical devices. Experiments were implemented varying recording location, mechanical barrier condition, and machine parameters. The …

High Speed Friction Stir Spot Welding On Dp 980 Steel:Joint Properties And Tool Wear, Nathan David Saunders

Theses and Dissertations

With the desire to improve passenger safety and fuel efficiency, Ultra High Strength Steels (UHSS) have been developed for use in the automotive industry. UHSS are high strength steels with high ductility and strength. DP 980 is one of these UHSS being applied in automobile manufacturing. DP 980 is difficult to join with Resistance Spot Welding (RSW) because of the high carbon content and alloying in this material. The weld becomes brittle when it solidifies during the welding process. With the desire and motivation of widely using UHSS, new welding processes are needed to be developed in order to effectively …

Effect Of Gold Content On The Microstructural Evolution Of Sac305 Solder Joints Under Isothermal Aging, Mike Powers, Jianbiao Pan, Julie Silk, Patrick Hyland

Industrial and Manufacturing Engineering

Au over Ni on Cu is a widely used printed circuit board (PCB) surface finish, under bump metallization (UBM), and component lead metallization. It is generally accepted that less than 3 wt.% Au in Sn-Pb solder joints inhibits formation of detrimental intermetallic compounds (IMC). However, the critical limit for Au content in Pb-free solder joints is not well established. Three surface-mount package platforms, one with a matte Sn surface finish and the others with Ni/Au finish, were soldered to Ni/Au-finished PCB using Sn-3.0Ag- 0.5Cu (SAC305) solder, in a realistic manufacturing setting. The assembled boards were divided into three groups: one …

Feasibility Analysis For Electrically-Powered Hoverboard, Cameron Chan, Jason Cortez, Jay Lopez

Aerospace Engineering

Composite materials are engineered by combining two or more constituent materials with significantly different physical or chemical properties in such a way that the constituents are still distinguishable, and not fully blended. Due to today’s high rising prices of gasoline and aviation fuel costs, many manufacturers have turned to the use of lightweight composites in their designs due to the advantages of the composite material, which include outstanding strength, excellent durability, high heat resistance, and significant weight reduction that the composite material properties hold. The purpose of this project is to design and construct a composite structure for an electrically-powered …

Lunalight Project: Solar-Rechargeable Led Lantern And Cell Phone Charger, Sean C. Dawson, Michael E. Deagen, Francisco N. Dye, Brian S. Mircheff, Ryan O. Ramelb

Materials Engineering

Today, 1.6 billion people in the world do not have access to grid electricity. Villagers living off the grid in developing nations resort to kerosene lanterns to light their homes. The fumes from burning kerosene are toxic and lead to respiratory illnesses over time. Our sponsor, OneMillionLights, plans to help people to escape poverty by providing them with a clean source of light at night. Children that must work in the fields during the day can use a solar-rechargeable lantern at night to read or study, and street vendors can use the lanterns at night to improve their businesses.

The …

The Morphology Evolution And Voiding Of Solder Joints On Qfn Central Pads With A Ni/Au Finish, Julie Silk, Jianbiao Pan, Mike Powers

Industrial and Manufacturing Engineering

In this paper, we report on a comprehensive study regarding the morphology evolution and voiding of SnAgCu solder joints on the central pad of two different packages – QFN and an Agilent package called TOPS – on PCBs with a Ni/Au surface finish. Samples were isothermally aged at the equivalent of 0, 2, 7 and 14 years service life. Representative solder joints were cross-sectioned and analyzed using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) in order to investigate the evolution of the solder joint morphology as a function of Au content and isothermal aging. IMC thickness was …

The Design And Fabrication Of A Microfluidic Reactor For Synthesis Of Cadmium Selenide Quantum Dots Using Silicon And Glass Substrates, Peter Robert Gonsalves

Master's Theses

A microfluidic reactor for synthesizing cadmium selenide (CdSe) quantum dots (QDs) was synthesized out of a silicon wafer and Pyrex glass. Microfabrication techniques were used to etch channels into the silicon wafer. Holes were wet-drilled into the Pyrex glass using a diamond-tip drill bit. The Pyrex wafer was anodically bonded to the etched silicon wafer to enclose the microfluidic reactor. Conditions for anodic bonding were created by exposing the stacked substrates to 300V at ~350oC under 5.46N of force. A syringe containing a room temperature CdSe solution was interfaced to the microfluidic reactor by using Poly (dimethylsiloxane) (PDMS) as an …

Introducing Fly Ash Into Lsi's Recipe, Andrew Mathias Beckrich

All Graduate Theses, Dissertations, and Other Capstone Projects

There has been published data that states that concrete producers can use Fly Ash as an alternative to Portland cement and still generate similar or better strength properties. By applying these principles to our industry and products, what new processes will need to be put in place and followed? What is the correct combination/portion of Fly Ash that will produce similar and better results as well as the adjusted new recipes? What type of cost is associated with the introduction of this new ingredient? Lastly, how does this affect the quality and reputation of the product?

Investigation Into The Usability Of Micromechanical Models To Predict The Behavior Of A Nanocomposite Polymer, Jason Handlogten

All Graduate Theses, Dissertations, and Other Capstone Projects

The purpose of this thesis was to determine the acceptability of a set of existing nanocomposite test specimens for tensile testing and then to determine the Young's and shear modulus of these test specimens. If the test specimens were found to be acceptable, the accuracy of three micromechanical models was to be evaluated by comparing their predictions to the mechanical properties determined from testing the specimens. The set of existing nanocomposite test specimens had a distinct concave shape on two surfaces that were believed to be intended as flat. In order to determine if they adhered to the Type I …

Generic Kinematic Simulation For Verification Of Laser Deposition Tool Paths, Sweta Dhaveji Chakravadhanula

Masters Theses

"The development of 3D visual simulation tool for machine simulation is a key approach in saving time and reducing cost. It is an important step before a manufacturing operation is performed on a part, as a tool to detect collision and validate the operation results. There are several kinds of manufacturing equipment being used and hence there is a need for the development of a generalized method to visually simulate a variety of machines. This paper presents the research conducted on describing machine configuration in a generic format which not only gives useful information, but can also be used as …

Fabrication Of Complex Ceramic Parts With Sacrificial Material Using Freeze-Form Extrusion Fabrication, Diego Armando Garcia MontañO

Masters Theses

"An additive manufacturing process called Freeze-form Extrusion Fabrication (FEF) was developed in this study to fabricate complex ceramic parts that require the use of sacrificial materials. The aqueous paste of alumina (Al₂O₃) was used as the main material, with solids loadings as high as 50 vol. % and water as the main liquid medium. Methyl cellulose, with a 10 vol. % solids loading and 90 vol. % water content, was used as the sacrificial material. The freeze-form extrusion machine has multiple extruders (extrusion devices) capable of fabricating parts from multiple materials without mixing them. The dynamic process of extruding alumina …

The Development Of A Predictive Probability Model For Effective Continuous Learning And Improvement, Michael Abbot Maginnis

Theses and Dissertations--Mechanical and Aerospace Engineering

It is important for organizations to understand the factors responsible for establishing sustainable continuous improvement (CI) capabilities. This study uses learning curves as the basis to examine learning obtained by team members doing work with and without the application of fundamental aspects of the Toyota Production System. The results are used to develop an effective model to guide organizational activities towards achieving the ability to continuous improve in a sustainable fashion.

This research examines the effect of standardization and waste elimination activities supported by systematic problem solving on team member learning at the work interface and system performance. The results …

Cryogenic Burnishing Of Co-Cr-Mo Biomedical Alloy For Enhanced Surface Integrity And Improved Wear Performance, Shu Yang

Theses and Dissertations--Mechanical and Aerospace Engineering

The functional performance of joint implants is largely determined by the surface layer properties in contact. Wear/debris-induced osteolysis and aseptic loosening has been identified as the major cause of failure of metal-on-metal joint implants. A crucial requirement for the long-term stability of the artificial joint is to minimize the release of debris particles.

Severe plastic deformation (SPD) processes have been used to modify the surface integrity properties by generating ultrafine, or even nano-sized grains and grain size gradients in the surface region of many materials. These fine grained materials often exhibit enhanced surface integrity properties and improved functional performance (wear …

Transport Phenomena Associated With Liquid Metal Flow Over Topographically Modified Surfaces, Wen Liu

Theses and Dissertations--Mechanical and Aerospace Engineering

Brazing and soldering, as advanced manufacturing processes, are of significant importance to industrial applications. It is widely accepted that joining by brazing or soldering is possible if a liquid metal wets the solids to be joined. Wetting, hence spreading and capillary action of liquid metal (often called filler) is of significant importance. Good wetting is required to distribute liquid metal over/between the substrate materials for a successful bonding.

Topographically altered surfaces have been used to exploit novel wetting phenomena and associated capillary actions, such as imbibitions (a penetration of a liquid front over/through a rough, patterned surface). Modification of surface …

An Empirical Study On Quality Management Practices, Organization Performance And Suppliers' Selection In Southern Minnesota Manufacturing Firms, Rachel Yetunde-Abiodun Awoku

All Graduate Theses, Dissertations, and Other Capstone Projects

Quality management systems (QMS) have been widely applied successfully by many manufacturing companies to improve their process, increase profits and organizational performance. The most applied of the quality programs are ISO 9001, Total Quality Management (TQM), Just-In-time (JIT), Lean Management and Six Sigma. Although past studies on quality management have identified and studied the implementation of quality management practices, there is little or no research on quality management practices and business performance in Southern Minnesota manufacturing companies. Many researchers have concluded that the implementation of quality management practices has led to significant improvements in companies' business performance while others have …

Development Of A Technique For Testing Of Tensile Properties With Miniature Size Specimens For Metal Additive Manufacturing, Sujitkumar Dongare

Masters Theses

"The study of mechanical properties of metals provides a basis to decide on the capability of a particular metal for a task and also to make predictions about its life. The concepts of stress, strain and strength of materials are employed in practically every engineering discipline. Mechanical properties such as stiffness, yield strength, tensile strength, ductility, toughness, impact resistance, creep resistance, fatigue resistance and others, influence the design, fabrication and service life of equipment. Therefore, more than one property is considered for the material selection process for an application. For complete understanding of any material and its feasibility for a …

Factors Impacting Technology Transfer: The Maquiladora Industry In Yucatan, Mexico, Ana Maria Canto, Carlos Blanco, Pilar Pazos

Engineering Management & Systems Engineering Faculty Publications

Technology transfer and knowledge transfer are the building blocks for innovation, efficiency and increased competitiveness. The topic of technology transfer in the context of multinational companies has been the focus of technology management researchers for well over two decades. Developing countries housing twin plans have been exposed to technology transfer from very diverse countries with different approaches to the technology transfer process and different levels of success. This cultural and national diversity adds an additional level of complexity to the technology transfer domain that has been largely unexplored. This paper will explore critical factors that had an impact in successful …

A Planning Tool To Predict The Welding Angle In Laser Metal Deposition, Sriram Prabhu

Masters Theses

"Research in Laser Metal Deposition (LMD) has been done rigorously in the past. However, the main challenge that still exists is the production of complex part geometries having overhang features. Production of such features requires individual tracks with a high aspect ratio and wider bead angle. The use of destructible/ non-destructible support structures involves costly post production operations which increase production cost. Tilting or moving the deposition surface can be useful to create overhangs but are applicable only to special cases. Since such techniques have to be used by the manufacturing community, the techniques need to be simple in calculation …

5-Axis Tool Path Generation With Collision Detection For Finish Machining Of Freeform Surfaces, Jomy Francis

Masters Theses

"Research in the field of Tool path generation for freeform surfaces has been done intensively in the past. However, the main challenge that still exists is the computational efficiency related to the tool path generation. Tool path generation for freeform surface involves instantaneous calculation of new tool orientations which does not collide with the neighboring surfaces. Since the collision check of tool and neighboring surface is done repetitively at every instant of the tool, the calculations at every instant are to be computationally as easy as possible.

This thesis is composed of one paper. Paper I presents a novel extension …